System and method for crimped-wires insertion to a connector machine

Abstract

A system and method for automatically inserting crimp contacts of a plurality of wires into holes of a connector is disclosed. Each hole of a connector has an electrical contact surface that is for electrical/physical contact with a designated part of a crimp contact. Thus, for proper electrical/physical contact, the connector and/or the crimp contact may be rotated to prepare for insertion of the crimp contact. As such, prior to the insertion, the connector and/or the crimp contact is rotated in an automatic orientation movement. After which, the automatic insertion movement is performed in which the crimp contact and/or the connector are moved so that the designated part of the crimp contact is in electrical/physical contact with the electrical contact surface of the hole. The automatic insertion movement may include the crimp contact being stationary and the connector is moving, or the connector being stationary and tire crimp contact moving.

1 . A method for automatically inserting crimp contacts of a plurality of wires into holes of a connector, the connector having within a plurality of electrical contact surfaces for electrical contact with the crimp contacts of the plurality of wires, the method comprising:
 for at least two of the plurality of wires, sequentially selecting a respective wire so that a designated part of the crimp contact of the respective wire physically contacts the electrical contact of a respective hole of the connector by:
 prior to performing an automatic insertion movement of one or both the crimp contact of the respective wire or the connector, performing an automatic orientation movement by moving one or both of the crimp contact of the respective wire or the connector in preparation the automatic insertion movement; and 
 after automatically performing the orientation movement, performing the automatic insertion movement of one or both the crimp contact of the respective wire or the connector by moving one or both of the crimp contact of the respective wire or the connector so that the designated part of the crimp contact physically contacts the electrical contact surface of respective hole of the connector; and 
   wherein the automatic orientation movement results in orientation of the designated part of the crimp contact and orientation of the electrical contact of a respective hole being the same so that the insertion movement, resulting in the physical contact of the designated part of the crimp contact with the electrical contact surface of the respective hole of the connector, consists of a lateral movement without any axial movement.   
     
     
         2 . (canceled) 
     
     
         3 . A method for automatically inserting crimp contacts of a plurality of wires into holes of a connector, the connector having within a plurality of electrical contact surfaces for electrical contact with the crimp contacts of the plurality of wires, the method comprising;
 prior to selecting a respective wire, spreading the plurality of wires;   for at least two of the plurality of wires, sequentially selecting the respective wire so that a designated part of the crimp contact of the respective wire physically contacts the electrical contact of a respective hole of the connector by:
 prior to performing an automatic insertion movement of one or both the crimp contact of the respective wire or the connector, performing an automatic orientation movement by moving one or both of the crimp contact of the respective wire or the connector in preparation the automatic insertion movement; and 
 after automatically performing the orientation movement, performing the automatic insertion movement of one or both the crimp contact of the respective wire or the connector by moving one or both of the crimp contact of the respective wire or the connector so that the designated part of the crimp contact physically contacts the electrical contact surface of respective hole of the connector. 
   
     
     
         4 . The method of  claim 3 , wherein spreading the plurality of wires results from crimping each of the plurality of wires with the crimp contacts and after crimping the plurality of wires, placing a crimped end of each of the plurality of wires in a predetermined place and in a predetermined orientation so that the plurality of wires are spread. 
     
     
         5 . The method of  claim 4 , wherein the predetermined place comprises a comb so that the each of the plurality of wires is positioned on the comb; and
 wherein inserting the end of the respective wire comprises using a gripper to grip the respective wire from the comb and moving the end of the respective wire into the connector.   
     
     
         6 . The method of  claim 4 , wherein the predetermined place comprises a flat surface; and
 wherein inserting the end of the respective wire comprises using a gripper to grip the respective wire from the flat surface and moving the end of the respective wire into the connector.   
     
     
         7 . A method for automatically inserting crimp contacts of a plurality of wires into holes of a connector, the connector having within a plurality of electrical contact surfaces for electrical contact with the crimp contacts of the plurality of wires, the method comprising;
 for at least two of the plurality of wires, sequentially selecting a respective wire so that a designated part of the crimp contact of the respective wire physically contacts the electrical contact of a respective hole of the connector by:
 prior to performing an automatic insertion movement of one or both the crimp contact of the respective wire or the connector, performing an automatic orientation movement by moving one or both of the crimp contact of the respective wire or the connector in preparation the automatic insertion movement; and 
 after automatically performing the orientation movement, performing the automatic insertion movement of one or both the crimp contact of the respective wire or the connector by moving one or both of the crimp contact of the respective wire or the connector so that the designated part of the crimp contact physically contacts the electrical contact surface of respective hole of the connector; and 
   wherein the plurality of electrical contact surfaces in the connector face different directions; and   wherein, for the respective wire, one or both of moving the connector or moving the crimp contact of the respective wire results in movement of one or both of: (i) a part of the crimp contact of the respective wire that is for physical contact with the electrical contact surface; or (ii) the electrical contact surface, so that the part of the crimp contact and the electrical contact surface are in alignment prior to insertion.   
     
     
         8 . The method of  claim 7 , wherein after spreading the plurality of wires, only rotating the connector is performed in order for the part of the crimp contact and the electrical contact surface to be in alignment prior to insertion. 
     
     
         9 . The method of  claim 8 , wherein the connector is held in a connector holder; and
 wherein the connector holder rotates, while holding the connector, in order for the connector to rotate in order for the part of the crimp contact and the electrical contact surface to be in alignment prior to insertion.   
     
     
         10 . The method of  claim 7 , wherein after spreading the plurality of wires, only rotating the part of the crimp contact is performed in order for the part of the crimp contact and the electrical contact surface to be in alignment prior to insertion. 
     
     
         11 . The method of  claim 10 , wherein, after gripping the respective wire with a gripper, the part of the crimp contact is rotated while the gripper is gripping the respective wire in order for the part of the crimp contact and the electrical contact surface to be in alignment prior to insertion; and
 after rotation of the part of the crimp contact, the gripper inserts the crimp contact into a respective hole of the connector.   
     
     
         12 . The method of  claim 11 , wherein the gripper grips an isolation layer of the respective wire; and
 while the gripper is gripping the isolation layer of the respective wire, a crimp contact orientation modifier is gripping at least a part of the crimp contact in order to rotate the crimp contact so that the part of the crimp contact and the electrical contact surface to be in alignment prior to insertion.   
     
     
         13 . (canceled) 
     
     
         14 . The method of  claim 1 , wherein the automatic insertion movement comprises maintaining the crimp contact stationary as the connector is moved;
 wherein at least a part of the respective wire is held by a gripper as the crimp contact is stationary; and   wherein, prior to movement of the connector toward the crimp contact that is stationary, a support structure is moved to contact at least a part of the gripper in order to brace the gripper in preparation for the connector moving to the crimp contact so that the part of the crimp contact is inserted within a respective hole of the connector.   
     
     
         15 . A system for automatically inserting crimp contacts of a plurality of wires into holes of a connector, the connector having within a plurality of electrical contact surfaces for electrical contact with the crimp contacts of the plurality of wires, the system comprising:
 a controller;   an automatic orientation movement device in communication with the controller and configured to perform an automatic orientation movement by moving one or both of the crimp contact of the respective wire or the connector in preparation for an automatic insertion movement; and   an automatic insertion movement device in communication with the controller and configured to perform the automatic insertion movement of one or both the crimp contact of the respective wire or the connector by moving one or both of the crimp contact of the respective wire or the connector so that a designated part of the crimp contact physically contacts the electrical contact surface of respective hole of the connector;   wherein the automatic orientation movement device is configured to perform the automatic orientation movement so that orientation of the designated part of the crimp contact and orientation of the electrical contact of a respective hole are the same so that the insertion movement, resulting in the physical contact of the designated part of the crimp contact with the electrical contact surface of the respective hole of the connector, consists of a lateral movement without any axial movement.   
     
     
         16 . (canceled) 
     
     
         17 . The system of  claim 15 , wherein the automatic orientation movement device comprises a gripper and at least one motor;
 wherein the gripper is configured to grip part or all of the crimp contact; and   wherein the at least one motor is configured to rotate the gripper in order to modify orientation of the crimp contact.   
     
     
         18 . The system of  claim 17 , wherein the gripper comprises gripper fingers that include a contact straightener that has a plurality of teeth in order to guide the crimp contact to the modified orientation. 
     
     
         19 . The system of  claim 15 , wherein the automatic orientation movement device comprises a connector holder and at least one motor;
 wherein the connector holder is configured to hold the connector; and   wherein the at least one motor is configured to rotate the connector holder, while the connector holder is holding the connector, in order to modify orientation of the connector.   
     
     
         20 . The system of  claim 19 , wherein the automatic orientation movement device further comprises a mounting block configured to mount to a plurality of different connector holders;
 wherein the plurality of different connector holders are for holding different types of connectors.   
     
     
         21 . (canceled) 
     
     
         22 . The system of  claim 15 , wherein the automatic insertion movement device is configured to move the connector as the crimp contact is stationary;
 wherein the automatic insertion movement device comprises at least one motor and a track device configured to move a support structure laterally via a track using the at least one motor;   wherein the support structure is connected to a connector holder;   wherein the connector holder is configured to hold the connector; and   wherein the automatic insertion movement device is configured to move the support structure laterally via the track so that the connector, held in the connector holder is moved to the crimp contact.   
     
     
         23 . The system of  claim 22 , wherein the automatic insertion movement device further comprises a gripper configured to grip the respective wire and hold the wire stationary as the connector holder moves laterally so that the connector contacts the crimp contact. 
     
     
         24 . The system of  claim 23 , wherein the automatic insertion movement device further comprises a side support device configured to move a side support into contact with the gripper so that the side support is configured to apply a force to at least a part of the gripper as the connector holder is moved so that the connector contacts the crimp contact. 
     
     
         25 . (canceled) 
     
     
         26 . The system of  claim 15 , wherein the automatic orientation movement device and the automatic insertion movement device include one or more common parts;
 wherein both the automatic orientation movement device and the automatic insertion movement device include a single connector holder;   wherein the single connector holder is configured to hold the connector;   wherein the single connector holder is configured to move radially in order to perform the automatic orientation movement; and   wherein the single connector holder is configured to move laterally in order to perform the automatic insertion movement.   
     
     
         27 . The system of  claim 26 , wherein at least a first motor is configured to move the single connector holder radially; and
 wherein at least a second motor is configured to move the single connector holder laterally.   
     
     
         28 . (canceled) 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . (canceled) 
     
     
         32 . The system of  claim 15 , wherein the controller is configured to select a sequence perform wire-by-wire automatic orientation movement and automatic insertion movement based on one or both of at least one aspect of the plurality of wires or positioning of the plurality of wires relative to one another or the connector;
 wherein the at least one aspect of the plurality of wires comprises color of insulation layer of the plurality of wires.   
     
     
         33 . The system of  claim 32 , wherein the controller is further configured to determine, based on at least one image, the positioning of wires relative to one another or the connector; and
 wherein the controller is configured to determine the sequence based on the positioning and based on the color of the insulation layer.   
     
     
         34 . The system of  claim 33 , wherein the controller is configured to select at least one wire based on the positioning and at least one wire based on the color of the insulation layer. 
     
     
         35 . A system for automatically inserting crimp contacts of a plurality of wires into holes of a connector, the connector having within a plurality of electrical contact surfaces for electrical contact with the crimp contacts of the plurality of wires, the system comprising:
 an automatic orientation movement device;   an automatic insertion movement device;   a controller in communication with the automatic orientation movement device and the automatic insertion movement device, the controller configured to:
 prior to selecting a respective wire, control spreading the plurality of wires; 
 for at least two of the plurality of wires, control sequentially selecting the respective wire so that a designated part of the crimp contact of the respective wire physically contacts the electrical contact of a respective hole of the connector by:
 prior to performing an automatic insertion movement of one or both the crimp contact of the respective wire or the connector, control the automatic orientation movement to perform an automatic orientation movement device by moving one or both of the crimp contact of the respective wire or the connector in preparation the automatic insertion movement; and 
 after automatically performing the orientation movement, control the automatic insertion movement device to perform the automatic insertion movement of one or both the crimp contact of the respective wire or the connector by moving one or both of the crimp contact of the respective wire or the connector so that the designated part of the crimp contact physically contacts the electrical contact surface of respective hole of the connector.